KHS has optimized its proven Innokeg Contikeg with respect to efficiency, hygiene and system safety and security
For almost 50 years, the KHS Innokeg Contikeg and its little brother Combikeg have been synonymous with innovation and top performance in the keg segment. The Dortmund systems supplier has now further developed its fully automatic machines to include keg washing and racking. These optimizations take line availability, safety, security and resource efficiency up to the next level. They also simplify operation and noticeably ease the load on personnel. This modernization reinforces KHS’ determination to actively drive technological development in keg racking and further strengthen its role as a turnkey line supplier across all container segments.
“In redesigning the Innokeg Contikeg and Combikeg, we’re impressively demonstrating that KHS is a strong technological partner to the keg business and is yet again able to supply its customers worldwide with powerful, future-proof plant engineering,” says Tobias Wetzel, CSO of KHS. KHS has pursued a clear objective with this further development, he continues. “We’ve taken our market-proven, extremely durable and valued keg technology into the next generation. It fully satisfies the high demands of the market and the expectations of our customers with respect to hygiene, safety, security and ergonomic operation. We’re thus facilitating maximum line availability, high production reliability and long-term competitiveness.” Moreover, he estimates that there’s a high growth potential for this equipment on the South American and Asian markets in particular.
Precise process control for gentler product handling
Designed for efficiency, flexibility and economy, using the continuous carousel principle the Innokeg Contikeg washes and racks up to 1,200 kegs per hour fully automatically. The sophisticated engineering enables a continuous process sequence: the kegs run through all production stages in the machine in rotary operation without having to be decoupled. This makes for a high level of performance and process stability. In processing containers holding between five and around 58 liters, the machine is suitable for a broad range of products – from whiskey soda, beer and mixed beer beverages through wine to water, soft drinks and juice.
KHS makes use of its pioneering, tried-and-tested Direct Flow Control (DFC) filling system for especially resource-conserving filling and gentle product handling. Unlike standard market procedures that regulate the filling speed by increasing the CO2 pressure in the container, the KHS system precisely controls the flow rate using the DFC valve. This reduces CO2 consumption by up to 40% and simultaneously ensures controlled, foam-free filling.
Modernization focuses on proven strengths
Efficiency is further increased by the use of an integrated, equally established central distributor, as Stefan Schuhriemen, head of the KHS Keg Technology Product Center, explains. “This controls the media feed from a central point, thus reducing the number of individual valve switches needed in the core process. In turn, this then lowers system complexity, minimizes wear and at the same time enhances process stability.”
KHS has also fundamentally redeveloped the machinery’s media supply. The previous L-shaped media transfer has been replaced by a new valve manifold already deployed in KHS’ filling technology portfolio. The standardized use thereof across various segments makes operation and maintenance easier and improves the global availability of spare parts.
Efficient operation and high line availability
The Innokeg Contikeg is distinguished by its intuitive operating system. Operators control the fully-automatic, high-performance machine from KHS’ tried-andtested ClearLine HMI operator panel. This localizes disruptions with absolute precision, making troubleshooting easier. As a result, line availability increases. The new messaging system also helps to ensure high machine availability: if there’s a fault on one of the racking heads, the machine only shuts down the affected head – fully automatically. Racking continues without interruption. On linear machines, on the other hand, the failure of just one station can bring the entire process chain to a halt. As with the racking head messaging system, KHS’ new IOLink technology also significantly simplifies diagnostics and maintenance here: if a sensor fails, the system accurately locates the disruption. Following manual replacement of the affected part, the respective parameters are automatically transferred to the new sensor so that the machine can quickly resume production.
Hygienic line design for sensitive beverages
The consistent further development of the Innokeg Contikeg is also evident in its hygienic design. Here, KHS has applied its proven washing concept, in which the hydromechanical cleaning process uses pulsating sprays with up to three different chemical cleaning media for sanitation. The incorporated soaking function also proves its worth when cleaning critical interior keg areas in particular, such as fittings and spring assemblies. “We paid strict attention to all aspects of hygiene when redesigning our kegging system. Among other things, we’ve simplified wiring by integrating a new valve manifold and thus eliminated possible risks to hygiene here. Hygienic line design is especially critical when processing sensitive beverages such as low- and no-alcohol or NoLo beers, as these make extremely high demands of microbiological safety,” Schuhriemen continues.
Up-to-the-minute line safety and cybersecurity
The Innokeg Contikeg optimization package also includes a thoroughly upgraded safety and security concept. By making numerous mechanical adaptations – from optimized safety switches on the doors through improved CO2 extraction to new protective housings – KHS once again meets the latest requirements made of machine and operator safety.
The revamped machine complies with the current DIN EN 415-2:2025 standard relevant to all machines and already satisfies the requirements of Regulation (EU) 2023/1230 on machinery, effective as of January 2027, and the EU’s Cyber Resilience Act. “As a machine and systems manufacturer, we’re obliged to provide proof of the conformity of our products with valid EU standards and regulations. This forms the basis of the CE mark and goods entry on the European market,” Schuhriemen states. Cybersecurity is also increasingly gaining significance regarding issue of the CE mark. In the future, manufacturers will be required to document that their products are protected against digital attacks. The EU’s Cyber Resilience Act and Radio Equipment Directive with their requirements of IT and OT security form the regulatory basis here.
KHS’ plug-and-produce Innokeg Combikeg – that fits into one shipping container – is also constructed using state-of-the-art technology. Unlike its big brother, it combines the entire line in a single compact machine and caters for a lower capacity range. It therefore provides its customers with a system that’s especially low on space and quick to integrate – and that already accounts for the provisions of the forthcoming revised EU machine regulation and the EU’s Cyber Resilience Act